System and method for custom forming a protective helmet for a customer&#39;s head

ABSTRACT

A custom-fitted helmet and a method of making the same can comprise, at a first location, obtaining head data for a customer&#39;s head comprising a length, a width, and at least one head contour. With at least one processor, generating a computerized three-dimensional (3D) headform matching the customer&#39;s head length, width, and head contour from the head data. The 3D headform can be compared to a helmet safety standard. At a second location different from the first location, a custom-fitted helmet based on the 3D headform can be formed, wherein the custom-fitted helmet satisfies the safety standard and comprises an inner surface comprising a topography that conforms to the length, width, and at least one contour of the customer&#39;s head. The first location can be a home or a store. Obtaining the head data from photographic images of a deformable interface member disposed on the customer&#39;s head.

RELATED APPLICATIONS

This application is a continuation of U.S. utility patent application17,026,475, filed Sep. 21, 2020, which is a continuation of U.S. utilitypatent application Ser. No. 16/231,805, filed Dec. 24, 2018, which is acontinuation of U.S. utility patent application Ser. No. 14/156,269,filed Jan. 15, 2014, which claims the benefit from U.S. provisionalpatent application 61/754,469, filed Jan. 18, 2013, U.S. provisionalpatent application 61/812,666, filed Apr. 16, 2013, U.S. provisionalpatent application 61/875,603, filed Sep. 9, 2013, U.S. provisionalpatent application 61/883,087, filed Sep. 26, 2013, the disclosure ofwhich are incorporated herein by this reference.

TECHNICAL FIELD

This disclosure relates to a system and method for custom forming aprotective helmet for a customer's head, such as a helmet for a cyclist,football player, hockey player, or motor sports participant. Inparticular, the system and method include equipment and methods forcapturing and receiving captured data from customers or potentialcustomers and arranging the data for three-dimensional analysis.

BACKGROUND

For helmet-wearing athletes in many sports, beyond the safety aspects ofthe protective helmet, additional considerations can include helmet fitand airflow through the helmet. Improvements in fit comfort and airflowcan reduce distractions to the athlete and thereby improve performance.Although the results of the method and system disclosed in this documentrelate primarily to safety, in addition to safety, improvements in fit,airflow, and comfort can also be achieved without reducing safety forparticular customers and customer head shapes.

Conventional helmet creation technology has designed helmets with theassumption that human heads are similar and that head circumference isthe most important factor in choosing an appropriate helmet. Adjustmentsto the standard helmet are then made by adding different thicknesses ofpadding between the customer's head and the inner surface of the helmet.These assumptions, however, have resulted in helmets that do not fitcorrectly, tend to slip around on the customer's head, rattle on thecustomer's head when vibration occurs in the customer's body duringactivities in the sport, or to create pressure points on the customer'shead and face to try to keep the helmet in place even though the paddingdoes not fit right or where the customer's head is too big to havepadding between the head and the helmet protective material. Systemsthat conform to a customer's head developed by Giro and Bell in the1990's do a remarkable job of stabilizing the helmet on a customer'shead. However, previously developed fit systems do not totally eliminatereliance on the requirement for additional padding by the customer toadapt the standard helmets to the customer's head for a more comfortablefit.

While scanning systems for human body parts are known, they suffer froma number of significant limitations and deficiencies. For example, thescanning equipment is expensive, bulky and requires the scanner and thesubject to be in the same place at the same time. This requirementlimits the easy and cost effective access for the general public as thescanner equipment is very expensive, difficult to transport and musthave trained personnel to use it. Additionally, some head shape scanningtechnologies are susceptible to false readings due to moisture on thehead and hair bulk. Conventional helmet creating technologies are notpractical for creating custom head shape helmets because they areexpensive and the molds are expensive. It is desirable to form a customfit helmet for customers without the need of expensive scanning andmanufacturing equipment, and to create that custom fit helmet quicklyand without requiring separate custom molds for each helmet.

SUMMARY

A need exists for a custom-fitted helmet and a method for making thesame. Accordingly, in an aspect, a method of making a custom-fittedhelmet can comprise, at a first location, obtaining head data for acustomer's head comprising a length, a width, and at least one headcontour. Generating, with at least one processor, a computerized threedimensional (3D) headform matching the customer's head length, width,and head contour from the head data. Comparing the 3D headform to ahelmet safety standard. At a second location different from the firstlocation, forming a custom-fitted helmet based on the 3D headformwherein the custom-fitted helmet satisfies the safety standard andcomprises an inner surface comprising a topography that conforms to thelength, width, and at least one contour of the customer's head.

The method of making the custom-fitted helmet can further compriseobtaining head data for the customer's head by obtaining images of adeformable interface member disposed on the customer's head, wherein athickness of the deformable interface member approximates a thickness ofa padding layer disposed within the custom-fitted helmet. Obtaining theimages can be accomplished by using an optical sensor, a camera, or alaser. Obtaining images of the deformable interface member that cancomprise measurement points. Obtaining images that can comprise a markerof a known size. Obtaining the head data can comprise gathering the headdata using a non-contact sensor positioned adjacent the customer's head.Updating a customer's head data can occur after at least six months bymeasuring at least the customer's updated head length and updated headwidth. Obtaining the head data at the first location by capturing aphotographic image of the customer's head can include the first locationbeing a customer's home, and sending the captured photographic image ofthe customer's head from the customer's home to the at least oneprocessor located a location remote from the customer's home. Obtainingthe head data at the first location can be accomplished by capturing aphotographic image of the customer's head, wherein the first location isa store, and sending the captured photographic image of the customer'shead from the store to the at least one processor located a locationremote from the store. The inner surface of the custom-fitted helmet canbe formed comprising a surface topography that is proportional to thelength, width, and at least one contour of the customer's head. Agraphical computerized 3D headform can be generated from the head data,the helmet safety standard can be provided as a graphical 3D helmetsafety standard, and the 3D headform can be compared to the helmetsafety standard by positioning the graphical 3D headform within thegraphical 3D helmet safety standard to determine a size and shape of theinner surface of the custom-fitted helmet. The helmet safety standardcan be provided comprising a certified surface. The helmet safetystandard can be provided comprising a test line. A helmet base unit canbe selected comprising a surface comprising a size and shape differentthan a size and shape of the inner surface of the custom-fitted helmetand the inner surface of the custom-fitted helmet can be formed byremoving expanded polystyrene (EPS) from the helmet base unit using acomputer numerical control (CNC) machine. The inner surface of thecustom-fitted helmet can be formed by an additive process. Forming theinner surface of the custom-fitted helmet can be accomplished byinserting a liner comprising a plurality of contiguous pieces or aplurality of separated pieces into a helmet base unit. The liner can beformed as a substantially flat array of pieces and a surface of thesubstantially flat array of pieces can be adjusted to mirror thecomputerized headform.

In another aspect, a method of making a custom-fitted helmet cancomprise obtaining head data for a customer's head, comparing the headdata to a helmet safety standard, and forming a custom-fitted helmetthat satisfies the safety standard and comprises an inner surfacecomprising a topography that conforms to the head data for thecustomer's head.

The method of making the custom-fitted helmet can further compriseobtaining head data for the customer's head length, width, and at leastone head contour. A graphical computerized 3D headform can be generatedfrom the head data, the helmet safety standard can be provided as agraphical 3D helmet safety standard, and the 3D headform can be comparedto the helmet safety standard by positioning the graphical 3D headformwithin the helmet safety standard to determine a size and shape of theinner surface of the custom-fitted helmet. The helmet safety standardcan be a graphical 3D helmet safety standard comprising a certifiedsurface. The graphical 3D helmet safety standard can comprise a testline. A helmet base unit can be selected to comprise a surfacecomprising a size and shape different than a size and shape of the innersurface of the custom-fitted helmet, and the inner surface of thecustom-fitted helmet can be formed by removing EPS from the helmet baseunit using a CNC machine. The helmet base unit can be formed comprisinga first protective material and a second protective material disposedadjacent to the first protective material, wherein the second protectivematerial is more easily removed that the first protective material, andthe custom-fitted helmet can be formed by removing a portion of thesecond protective material. The custom-fitted helmet can be formedcomprising posts configured to interface with a jig to stabilize thecustom-fitted helmet during forming. The inner surface of thecustom-fitted helmet can be formed by an additive process. The innersurface of the custom-fitted helmet can be formed by inserting acustom-fitted liner into a stock helmet. Head data for the customer'shead can be obtained by obtaining images of a deformable interfacemember disposed on the customer's head, wherein a thickness of thedeformable interface layer corresponds to a thickness of a padding layerwithin the custom-fitted helmet.

In another aspect, a method of making a custom-fitted helmet cancomprise, at a home or at a store, obtaining head data for a customer'shead, and at a location remote from the home or retail store, forming acustom-fitted helmet that comprises an inner surface comprising atopography that conforms to the head data for the customer's head.

The method of making the custom-fitted helmet can further compriseobtaining head data for the customer's head by obtaining images of adeformable interface member disposed on the customer's head, wherein theimages comprise a marker of a known size. A graphical computerized 3Dheadform can be generated from the head data, a helmet safety standardcan be provided as a graphical 3D helmet safety standard, and the 3Dheadform can be compared to the graphical 3D helmet safety standard bypositioning the graphical 3D headform within the graphical 3D helmetsafety standard to determine a size and shape of the inner surface ofthe custom-fitted helmet. The graphical 3D helmet safety standard cancomprise a certified surface. The graphical 3D helmet safety standardcan further comprises a test line. Head data can be obtained byobtaining a length and a width of the customer's head based ontwo-dimensional (2D) measurements. A helmet base unit can be selected tocomprise a surface comprising a size and shape different than a size andshape of the inner surface of the custom-fitted helmet, and the innersurface of the custom-fitted helmet can be formed by removing EPS fromthe helmet base unit using a CNC machine. The graphical 3D headform canbe positioned within the graphical 3D helmet safety standard to optimizea field of view (FOV) for the customer.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 shows a mechanical measurement tool.

FIGS. 2A-2C show an embodiment of a customer wearing a deformableinterface member.

FIGS. 3A-3B show another embodiment of a customer wearing a deformableinterface member.

FIGS. 4A-4C show a 3D headform generated by modeling software.

FIGS. 5A-5C show head data being compared to a helmet safety standardfor forming a custom-fitted helmet.

FIGS. 6A-6F show a custom-formed helmet compared against a helmet safetystandard.

FIGS. 7A-7D show forming a custom-fitted helmet including a finishedinner surface comprising a topography that matches a customer's head.

FIGS. 8A and 8B show another embodiment of a custom-fitted helmet.

FIGS. 9A and 9B show other embodiments of a custom-fitted helmets.

FIGS. 10A and 10B show other embodiments of a custom-fitted helmets.

DETAILED DESCRIPTION

This disclosure, its aspects and implementations, are not limited to thespecific helmet or material types, or other system component examples,or methods disclosed herein. Many additional components, manufacturingand assembly procedures known in the art consistent with helmetmanufacture are contemplated for use with particular implementationsfrom this disclosure. Accordingly, for example, although particularimplementations are disclosed, such implementations and implementingcomponents may comprise any components, models, types, materials,versions, quantities, and/or the like as is known in the art for suchsystems and implementing components, consistent with the intendedoperation.

The word “exemplary,” “example,” or various forms thereof are usedherein to mean serving as an example, instance, or illustration. Anyaspect or design described herein as “exemplary” or as an “example” isnot necessarily to be construed as preferred or advantageous over otheraspects or designs. Furthermore, examples are provided solely forpurposes of clarity and understanding and are not meant to limit orrestrict the disclosed subject matter or relevant portions of thisdisclosure in any manner. It is to be appreciated that a myriad ofadditional or alternate examples of varying scope could have beenpresented, but have been omitted for purposes of brevity.

While this disclosure includes a number of embodiments in many differentforms, there is shown in the drawings and will herein be described indetail particular embodiments with the understanding that the presentdisclosure is to be considered as an exemplification of the principlesof the disclosed methods and systems, and is not intended to limit thebroad aspect of the disclosed concepts to the embodiments illustrated.

This disclosure provides a system and method for custom forming aprotective helmet for a customer's head, such as a helmet for a cyclist,football player, hockey player, baseball player, lacrosse player, poloplayer, equestrian rider, rock climber, auto racer, motorcycle rider,motocross racer, skier, skater, ice skater, snowboarder, snow skier andother snow or water athlete, sky diver or any other athlete in a sportor other person including soldier, pilot, or other military person, whois in need of protective head gear. Each of these sports uses a helmetthat includes either single or multi-impact rated protective materialbase that is typically, though not always, covered on the outside by adecorative cover and includes comfort material on at least portions ofthe inside, usually in the form of padding. Other sports, such as boxingsparring, wrestling and water polo use soft helmet types. Soft helmettypes can also benefit from particular aspects of the disclosed methodsand system through custom fit soft helmets. Other industries also useprotective headwear, such as a construction, soldier, fire fighter,pilot, or other worker in need of a safety helmet, where similartechnologies and methods may also be applied. The method, system, anddevices described herein are discussed with particular reference toheads and custom-fitted helmets, the same or similar methods, systems,and devices are applicable to other body parts and corresponding gear orclothing.

Human heads are each very different. Even if two people have the samehead circumference, they may have different relative length and widthmeasurements, and certainly have different head topographies.Conventional helmet sizes, small, medium, large, extra large, etc., aregenerally based on head circumference. If a customer's headcircumference is a particular circumference, the customer may try aparticular generic helmet size that does not fit because the customer'shead is longer or wider than “normal,” and is different from the generichelmet size, such that the customer may try wearing the next largergeneric helmet size. However, the customer's head may have had a headshape that includes a width that is substantially equal to a first orgeneric small width, while the customer's head further includes a lengththat is substantially equal to a second or generic medium length. In asuch a situation, putting the customer into a medium sized helmetresults in the helmet not fitting as well as it could because the helmetwidth is now too big and must be filled by extra padding. By studyingmany different head shapes and the fit of helmets to those respectivehead shapes, it has been discovered that head length and width are themost important measurements on a head in determining a comfortable fitand providing a good match between a customer's head topography and atopography of the helmet. It has also been discovered that matching alength and width of a customer's head to a length and width of thecustomer's helmet is more important than only matching a circumferenceof the customer's head to a circumference of the customer's helmet.Additionally, matching a topography of the customer's head to atopography of the customer's helmet also plays a significant role indetermining a good fit for comfort and safety. As additional data onmore and more head shapes and topography continues to be gathered andstudied, additional classifications of head shapes may be discovered tofurther refine the processes described herein.

Accordingly, this disclosure relates to a system for manufacturing acustomer specific custom-fitted helmet that matches a customer'sparticular head size and topography to a helmet that is createdspecifically for that customer. The system may be implemented through acomputer interface or other method that receives the customer's headdata and then manufactures a custom-fitted helmet unique to thatcustomer's head data. As an overview, a particular non-limitingembodiment comprises receiving captured customer head data, analyzingthe received data for comparison with safety standards, a pre-determinedthickness or other standards, creating an acceptable 3D model for atleast portions of the helmet internal surface, and creating a customhelmet specific to the customer's data received.

A protective helmet customer's head data may be gathered in a variety ofdifferent levels of detail and manners. Particular embodiments of thesystems and methods disclosed are improved and more useful with moredata received, but the systems and methods are not limited to capturingthe full level of detail in every instance. For example, althoughcapturing a full 3D model and topographical layout of a customer's headmay be accomplished using, for example, a non-contact or optical sensorsuch as a laser, an optical micrometer, photographic camera, or videorecorder, in many cases just the customer's head length and head widthmeasurements may be used to create a custom helmet for the customerthrough embodiments of the system and method. It is intended thatalthough particular more complete levels of data capture are describedherein, any of the embodiments may be implemented with any level of datacapture detail by either substituting in standard data for any missingdata, or by comparison with other similar head shapes to customize tothe most likely head topography for the customer from other customerdata with acceptable margins.

Customer head data may be captured with the customer present through theuse of mechanical measurement tools such as a ruler, tape measure, orcalipers, or through optical tools such as a 2D photo or series ofphotos or video that can later be broken down by frames to extract thedata, through physical casting of the customer's head, through lasermicrometers, touch probes, magnetic resonance imaging, CT scanning,radio wave scanning, micrometer scanning of the customer's head orportions of the customer's head, and any other method known forgathering measurement data relating to the outer surface of thecustomer's head. Those of ordinary skill in the art will readilyunderstand how to extract the data into a usable form from theparticular data gathering method chosen. FIG. 1 shows an exemplarytwo-dimensional head measurement tool 10 that includes a ruler 12, aslidable member 14, and pads 16, configured to be disposed against acustomer's head or in contact with another body part or object to bemeasured. By adjusting slidable member 14 until pads 16 are touching, oradjacent to, opposing portions of a customer's head or other body part,an accurate 2D distance can be obtained.

FIGS. 2A-2C show a particular, non-limiting example of how biometricdata of a customer 20 may be captured and received from a customerwearing a deformable interface member 22 for a custom fit helmet.Deformable interface member 22 comprises a flexible sleeve or tube thatcan be made of a thin, resilient, radially stretchable material designedto conform and contour to at least a portion of customer 20. Deformableinterface member 22 can comprise a loose-knit fiber breathablyconfigured to allow airflow during use. Providing breathableconfigurations of deformable interface member 22 can be of particularbenefit when the deformable interface member is disposed over a face ofcustomer head 30. Deformable interface member 22 can be formed of afiber or loose-knit fiber or material that can be any one of a number ofstretchable or elastic materials, including NYLON, LYCRA, SPANDEX,BIOSKIN, EpX, or other suitable commercially available material.

FIG. 2A shows customer 20 wearing a deformable interface member 22 thatis configured as a tight fitting cap or head piece 26 disposed over aportion of customer head 30. Cap 26 can be disposed over the customer'scrown and a top portion of customer head 30 without covering an entiretyof customer head 30 including the face of customer 20. The portion ofcustomer head 30 covered by cap 26 can correspond to a portion ofcustomer head 30 that will be covered by the customer's custom-fittedhelmet. In some instances, a size of the portion of customer head 30covered by the deformable interface member 22 will be equal to orgreater than a size of a portion of customer head 30 that will becovered by the customer's custom-fitted helmet.

For the measurement of most heads, by wearing a deformable interfacemember 22, at least a portion of the customer's hair 32 can be pressedflat against customer head 30. Because most customers have some hair,and at a minimum the deformable interface member 22 has a thickness,even when deformable interface member 22, such as cap 26 is designed tofit tightly on customer head 30, a gap or offset will exist between asurface of customer head 30 (such as the scalp) and an outer surface 34of deformable interface member 22. In most if not all cases, margins oferror for the gap between the surface of customer head 30 and the outersurface 34 of deformable interface member 22 is small enough to not becritical to the processes for creation of a custom helmet. Morespecifically, a thickness of the customer hair 32 under the deformableinterface material is often a good approximation of a thickness ofcustomer hair 32 that will be accommodated between customer head 30 andan inner surface of the customer's customized helmet. Alternatively, aknown or approximate thickness of the deformable interface member 22, athickness of the customer's hair 32, or both can be subtracted from ameasurement of the outer surface of deformable interface material 22 toproduce a better approximation of an actual measurement of customer head30.

In an embodiment, a thickness of deformable interface material 22 can beselected to be equal to a thickness of subsequently added comfortpadding. Thus, deformable interface material 22 can provide a desiredoffset for subsequently included comfort padding, such as padding ofinterface layer 84, without a need for performing costlypost-measurement or post-processing computer aided drafting (CAD) work.By directly measuring a good and viable approximation for a surface 85of padding 84, an amount of expensive CAD work needed for generating acustom inner surface 82 of a custom-fitted helmet 81 is reduced, therebyproviding a streamlined and cost-effective process for modeling andgenerating custom-fitted helmets 81. Accordingly, any gap between thescalp of a customer head 30, including customer hair 32 and a thicknessof deformable interface member 22, can be accounted for in a variety ofways according to the application and design of the modeling process.For convenience of discussion, the present disclosure will at timesrefer to the head data gathered from an outer surface of deformableinterface material 22 as the customer's head data relevant to thesurface of the customer head 30, and not as an approximation. However,the measurement of customer head 30 can also include an offset forpadding 84.

In a particular embodiment, cap 26 used for the initial measurements ofcustomer head 30 comprises a thickness of approximately 1.5 mm (made ofneoprene in particular embodiments). It has been found that for somewearers, like track racers, a tighter fit is more desirable than forother wearers, like street riders, who are used to a looser fit on theirhead. In particular embodiments described below, the surface of the 3Dheadform 66 is used as the cutting surface for the customization processfor the inner surface of the base unit. In other embodiments, additionalcalculations are made to virtually add a layer between the wearer's headand the cut surface before the cut surface is defined and the cuts aremade. By having the wearer wear a cap that includes a predeterminedthickness that is chosen to allow a particular offset between thewearer's head and the internal surface of the final custom helmet, theadditional calculations are not needed. This reduces processing time andsignificantly simplifies the cutting surface calculations.

In one particular embodiment, three different cap thicknesses are usedas options for a wearer depending upon the wearer's preferences and theultimate purpose for the helmet created. In a particular embodiment, afirst cap thickness is 1.5 mm, a second cap thickness is 3.0 mm and athird cap thickness is 4.5 mm. These examples are non-limiting and userpreferences are different and uses for the helmets are different so thatany range of cap thicknesses and any number of caps is contemplated foruse with various embodiments. In another particular embodiment, insteadof, or in addition to, separate caps being used, a wearer may applymultiple caps simultaneously to obtain a thicker offset. For example, awearer may apply three 1.5 mm caps to obtain a cap thickness of 4.5 mm.Thus, a wearer may indicate a preference as to how tight they want theirfinal helmet to fit and without requiring additional complexcalculations the system can automatically adapt the final cut linehelmet model to compare with the headform by simply applying aparticular thickness of cap or multiple caps of the same or differentthicknesses during data capture.

In other particular embodiments, the cap thickness may be selected toautomatically establish a padding offset or the padding offset combinedwith a comfort offset, without the system further calculating a 3Doffset from the wearer's measured head data. By incorporating the offsetinto the cap thickness, the offset that ordinarily would have beencalculated by the computer system may be automatically accounted forthrough a thicker cap. Provided the cap material fits closely to thewearer's head, like neoprene or nylon or another elastic and flexible,form fitting material, this method may be used to establish the desiredoffset without further calculating of a separate cutting surface.

As shown in FIGS. 2A-2C, cap 26 includes a reference or grid pattern 28comprising horizontal and vertical lines. However, reference pattern 28can comprise vertical lines, skewed lines, intersecting lines, bars,squares, circles, diamonds, hatching, or any geometric pattern, organicpattern, stochastic pattern, or any other design of suitable shapes,colors, patterns, or forms. As illustrated in FIGS. 2A-2C, thehorizontal lines may be further configured as major horizontal referencelines 36 and minor horizontal reference lines 38 separated by knowndistances. For example, FIG. 2A is a side view of customer head 30wearing cap 26 that includes, in an embodiment, three major horizontalreference lines 36 formed around circumferences of differing sizes alonginterface member 22. FIG. 2A additionally shows a plurality of minorhorizontal reference lines 38 spaced at known or even intervals that canbe spaced at a fixed distance between each of the major reference lines36. In an embodiment, as illustrated in FIG. 2A, 5 minor reference lines38 are disposed between each adjacent pair of major reference lines 36,although any number of reference lines can be used. In addition,interface member 22 can also include vertical reference lines 40 thatare perpendicular or normal to the horizontal reference lines. As shownin FIG. 2C, a top view of cap 26 is shown in which interface member 22includes a first vertical reference line 40 a extending between frontand back portions of customer head 30 in a direction of a length L ofthe customer head. Similarly, interface member 22 is also shownincluding a second vertical reference line 40 b extending betweenopposing sides of customer head 30 in a direction of a width W of thecustomer head, in which the vertical reference line 40 a intersectsvertical reference line 40 b at a perpendicular angle, or an angle ofapproximately 90 degrees. Therefore, reference lines 36, 38, and 40 forman exemplary reference pattern 28 that can show a shape, contour, ortopography of customer head 30, and can be used in collecting data forthe customer head, including length, width, and at least one contour ofthe customer head. For example, vertical line 40 a can follow anddelineate a contour of customer head 30 along a peak or ridge of thecustomer head along its length. Similarly, vertical reference line 40 bcan follow and delineate a contour of customer head 30 along a peak orridge of the customer head along its width. Additionally, a plurality ofother contour lines can also be captured by any number of differentreference patterns 20.

As shown in FIGS. 2A and 2B, cap 26 can also include measurement points42. Deformable interface member 22 can include any number of measurementpoints, and in an embodiment, includes at least four measurement points42 located on a left side, right side, front and rear portion ofdeformable interface member 22 and in-line or overlapping with verticalreference lines 40 a and 40 b. Deformable interface member 22 canfurther include an orientation device 44 that may be located at anuppermost extent of deformable interface member 22 or at an intersectionof vertical reference lines 40. Orientation device 44 helps facilitateimaging of deformable interface member 22, such as by photographs, andcan further facilitate subsequent compilation or assimilation of theimages to provide a comprehensive data set or headform of customer head30, as discussed in greater detail below. Orientation device 44 can besized and shaped in any suitable configuration and material. Forexample, orientation device 44 can be configured as one or more plastictubes formed into any shape to provide relative orientation betweendeformable interface member 22 and customer head 30.

Thus, a non-limiting example of a particular method for obtaining headdata can be understood with respect to FIGS. 2A-2C. First, customer 20wears cap 26 on customer head 30. Next, an initial set of referencemeasurements are taken of measurement points 42 while customer 20 iswearing an interface member 22 such as cap 26. For example, measurementscan be taken along vertical reference lines 40 a and 40 b from thefront, rear, left, right, and top sides of deformable interface member22. The method can further include orientation device 44 aligned withdeformable interface member 22 when measuring the deformable interfacemember. The measurement of deformable interface member 22 can be donedirectly with the interface member, such as by using head measurementtool 10, or other suitable 2D or 3D measurement tool, or by taking aplurality of photographs of the interface member while worn on customerhead 30. Photographs can be taken of left, right, front, rear, and topviews of the customer's head, including measurement points 42 andorientation device 44. Measurements can also be made of customer head 30by collecting data from the photographs or from a 3D headform or modelthat is constructed from the customer head data. Because cap 26 caninclude major horizontal reference lines 36, minor horizontal referencelines 38, vertical reference lines 40, measurement points 42, andorientation device 44, more data can be gathered during imaging fordetermining a more complete model of the topography of customer head 30.

FIGS. 3A and 3B show another variation of a method for obtainingconsumer head data for customer 20 wearing a deformable interface layer22. More specifically, FIG. 3A shows a front view of customer 20 wearinga deformable interface member 22 configured as a tight form fittingheadpiece or mask 50 disposed over an entirety of customer head 30 andthe customer's face, which facilitates obtaining head data for anentirety of the customer head 30. Obtaining head data for an entirety ofcustomer head 30 can be obtained, as described above, by use of one ormore mechanical measurement tools, optical tools, or both. As anon-limiting example, head data can be obtained for customer head 30while wearing headpiece 50 by capturing photos of customer head 30.Photographs or images of headpiece 50 can be obtained for multiple viewsand from multiple angles relative to customer head 30. A greater numberof photos can capture a greater amount of detail of customer head 30such that a better custom fit for a custom-fitted helmet can bepossible. In an embodiment, five images or photographs are taken of acustomer's head 30 wearing deformable interface member 22, the fiveimages including a front view, a back view, a left view, a right view,and a top view.

As shown in FIG. 3A, a width (W) of customer head 30 can be measured bytaking a distance from opposing outer edges of customer head 30 in thecoronal plane. As shown in FIG. 3B, a length (L) of customer head 30 canbe measured by taking a distance from opposing outer edges of customerhead 30 in the sagittal plane. Thus, a length L and width W of customerhead 30, as well as a general shape of customer head 30, can be obtainedby imaging customer head 30. Additionally, contours of customer head 30can also be obtained. Exemplary contours can include a first contour 54that includes a crest or ridgeline along a peripheral edge of customerhead 30 as seen in FIG. 3A or a second contour 56 that includes a crestor ridgeline along a peripheral edge of customer head 30 as seen in FIG.3B. A plurality of other contours can also be obtained for differentcrests and ridgelines along a peripheral edge of images or photographstaken at different relative angles with respect to customer 20. Agreater number of contours can provide a greater amount of detail of theshape and topography of customer head 30 such that a better custom fitfor a custom-fitted helmet can be possible.

As shown in the front view of FIG. 3A and the side view of FIG. 3B,headpiece 50 does not include a reference or grid pattern such as thereference pattern 28 shown in FIGS. 2A-2C. Instead a marker or referenceitem 52 is used to indicate relative size of customer head 30 andfacilitate scaling of dimensions from the captured images or scans. Assuch, marker 52 comprises known dimensions, and can include a fixedfeature positioned adjacent to the customer when the customer wearingheadpiece 50 is imaged or the head data is obtained. Marker 52 alsocomprises movable items that can be held or positioned by customer 20for imaging. For example, FIG. 3A shows customer 20 holding a coin asmarker 52 to provide a relative distance or scale for measuring orcalibrating the head data obtained from imaging headpiece 50. Thus, byincluding marker 52 within a photograph of customer 20 wearing headpiece50 taken at a first location, the relative dimensions of head 30 can beanalyzed at a time after the photo is taken, and at a second locationthat is different or remote from the first location.

For example, the first location can be at a home or residence, such asthe customer's home, where customer head data collection can beobtained, for example, through imaging, measuring, or photographing inthe convenience of the home of customer 20. Additionally, the firstlocation can also include a store, kiosk, tradeshow, or other event orlocation at which images or data of customer head 30 can be captured.When capturing head data at the first location, customer 20 or anotherindividual assisting the customer can take or capture one or morephotographs with a discrete or stand alone camera. Alternatively, one ormore photographs can be captured by a camera that is integrated with acomputer, tablet, or handheld electronic device. The integrated cameracan also be associated or paired with an application or software programthat includes instructions or directions that guide or prompt customer20 or other user or helper through a process of obtaining or acquiringthe appropriate images of photographs. Interactive applications andsoftware can also adaptively adjust a number and type of images taken inorder to ensure adequate and proper data for subsequent helmetcustomization. For example, a stationary camera coupled to a computerprogram can take a series of photos at one or more fixed time intervals.The interactive program can also prompt the customer to positioncustomer head 30 at useful positions for each image captured, such thatthe customer is directed to change their head position relative to thecamera during each time interval to provide multiple pictures atdifferent angles, such as pictures of a front, side, and back ofcustomer head 30. Based on the quality of data received, the toleranceor sizing required for a final custom-fitted helmet, the interactivesoftware can prompt customer 20 or an assistant to take additionalphotographs or retake low quality and out-of-focus or misalignedphotographs to ensure sufficient and proper head data is obtained tomake the custom-fitted helmet. The interactive application can also beconfigured to enable the customer to select other customizations for thecustom-fitted helmet.

The head data obtained for customer 20 need not be restricted to asingle use or customized-fitted helmet. Instead, the data gathered forcustomer 20 can be entered into database 24 and used to establish acustomer profile for later processing, analysis, and manufacture.Because, after a particular age, a shape and size of customer head 30will not change significantly, the customer's profile may be saved forsome time and used for future custom helmet orders. Updating head datafor customer head 30 can occur at regular or fixed intervals based onthe customer's age, the customer's anticipated growth, or in conjunctionwith athletic seasons and schedules. For example, a customer's head datacan be updated at least every year, or at least every six months bymeasuring at least one or more of the customer's updated head length,updated head width, or updated head contour.

Thus, customer head data, once captured, and before or after refinementof the data, can be sent from the first location to a second locationremote from the first location. The customer head data may betransmitted to database 24 in which head data is centralized for furtherprocessing, analysis, and manufacture of a custom helmet, as discussedin greater detail below. The data may be transferred in any way todatabase 24 such as, but not limited to, entry into and transmissionthrough a computer over the Internet or other transmission method,mailing the data records, or a store employee, customer assistant oreven the customer calling someone associated with database 24 andrelaying the data.

FIGS. 4A-4C show that after obtaining head data for customer 20, thehead data can be used to generate a computerized 3D headform matching alength, width, and head contour of customer head 30 using at least oneprocessor and a 3D modeling program 60. Before the computerized 3Dheadform is generated, the customer's head data can be furtherprocessed, if needed, and analyzed for the specific measurement datarelevant to customer head 30. For embodiments where customer head datais captured as images, commercially available image analysis softwarecan be used as 3D modeling program 60 to create an approximate 3D imageor at least a 3D array of reference points for use in approximating thesurface of customer head 30. FIG. 4A shows a non-limiting example ofcommercially available image analysis software 62, 123D Catch, which isproduced by Autodesk, and can be used as a program for 3D modeling.Whether the surface data is modeled as a 3D solid, a 3D surface, a pointcloud, a data array, a polygonal mesh, or any other surface modelapproximation method, the data may be used to approximate the surface ofcustomer head 30 for purposes of this disclosure.

In an embodiment, head data for customer 20, such as photographs, can beimported into image analysis software 62 such that photographs of thecustomer are placed on corresponding reference planes, such as coronal,sagittal, and transverse planes, and are dimensioned based on themeasurements taken, such as the measurements from the measurement points42 or from marker 52. 3D modeling program 60 generates a representationof customer head 30 and can include a 3D pattern that matches referencepattern 28, if present. Accordingly, 3D lines can match major and minorhorizontal reference line 40 a and 40 b, respectively, as well asvertical reference lines 40, if present, to each of the correspondingreference planes. Using the 3D curves, the modeling program creates asurface that connects all of the curves to form a 3D headform orgraphical representation 66 of the customer's head 30, as shown in FIG.4B. 3D headform 66 closely corresponds to a topography or the length,width, and at least one contour of customer head 30. Notably, 3Dheadform 66 can be offset by a predetermined amount to accommodate thethickness of the helmet's internal liner and/or internal paddingassembly.

FIG. 4B shows a 3D headform 66 for an upper or top portion of customerhead 30 for forming a custom-fitted helmet that only covers the topportion of customer head 30. Alternatively, headform 66 can be for anentirety of customer head 30, including the face, chin, and neck, and beused for forming a custom-fitted helmet that covers only a top portionof customer head 30 or an entirety of customer head 30 including theface, chin, and neck.

As shown in FIG. 4C, graphical representation 66, including any offset,can be imported into a 3D tooling model 70 and points of the graphicalrepresentation 66 are aligned with corresponding points of the toolingmodel. The headform of tooling model 70 can be made to expose a shape ofcustomer head 30. A headform may be created, such as by a 3D printer orother method, to create a specific mold for use in creating acustom-fitted helmet. Alternatively, a helmet base unit may be sculptedto match the contours of customer head 30. Either way, the result is acustom-fitted helmet formed from the customer's 3D headform 66 toprovide a custom-fitted helmet that is customized to the topography orthe length, width, and at least one contour of customer head 30.

FIGS. 5A-5C show a comparison between 3D headform 66 and a helmet safetystandard 71. 3D headform 66 can be used in an automated or graphicvisual comparison with helmet safety standard 71 stored in associationwith processors associated with database 24. In particular embodiments,a protective base material can be disposed between an outer surface 83of custom-fitted helmet 81 and a custom inner surface 82 of the helmet.Protective base material 72 can be formed of an energy absorbingmaterial or energy attenuating material such as EPS, expandedpolypropylene (EPP), plastic, foam, expanded polyethylene (PET), vinylnitrile (VN), polyurethane (PU), ethylene-vinyl acetate (EVA), cork,rubber, orbathane, EPP/EPS hybrid (Zorbium), EPLA, brock foam, or othersuitable material or blended combination or hybrid of materials.Protective base material 72 can protect customer 20 and customer head 30through absorbing or attenuating energy during impacts by plastically orelastically deforming. In an embodiment, for example, EPS foam can becrushed during impact to protect customer head 30 during an impact.Protective base material 72 can be provided in such a way as to ensurethat protective base material 72 meets predetermined minimum dimensions(DM) as required by safety standard 71. Minimum dimensions DM can bespecified by particular safety regulations or standards of the sport oractivity to which the helmet applies, by particular manufacturingspecifications or realities for manufacture of the helmet, or by agoverning or regulatory bodies. Exemplary regulatory bodies andstandards as known by persons in the art include standards establishedby the International Standards Organization (ISO), the United NationsEconomic Commission for Europe (ECE) testing standards, as commonlyapplied in Europe, the United States Department of Transportation (DOT),and the Snell Memorial Foundation (a not for profit organizationdedicated to research, education, testing, and development of helmetsafety standards).

As shown in FIG. 5A, 3D headform 66 of customer 20 can be automaticallyor graphically compared to helmet safety standard 71, including minimumdimensions DM, to determine suitable sizing and dimensions forcustom-fitted helmet 81. Based on 3D headform 66 and minimum dimensionsDM, custom-fitted helmet 81 can be formed comprising a custom innersurface 82 c comprising a topography that conforms to the length, width,and at least one contour of customer head 30. As shown in FIG. 5B,actual dimensions (DA) as measured for custom-fitted helmet 81, aregreater than or exceed the minimum dimensions DM required by helmetsafety standard 71. As shown in FIG. 5C, actual dimensions DA asmeasured for custom-fitted helmet 81, can be greater than or equal tothe minimum dimensions DM required by helmet safety standard 71. In someinstances, a first portion of custom inner surface 82 c can be formedsuch that a thickness or distance between custom inner surface 82 c andouter surface 83 can be substantially equal to or approximate a minimumdimension DM required by helmet safety standard 71. As shown in FIG. 5C,the portion of custom inner surface 82 c disposed over a top portion orcrown of customer head 30 such that a thickness or distance betweencustom inner surface 82 c and outer surface 83 is substantially equal tominimum dimension DM. Accordingly, a second portion of custom innersurface 82 c can be formed such that a thickness or distance betweencustom inner surface 82 c and outer surface 83 is greater than a minimumdimension DM required by helmet safety standard 71, such as the portionsof custom inner surface 82 c disposed around a periphery or outside thetop crown portion of customer head 30.

FIGS. 6A-6F, similar to FIGS. 5A-5C, show an embodiment in whichcustom-formed helmet 81 is compared against a helmet safety standard 71that includes more than a minimum thickness of protective base material72 to satisfy the helmet safety standard. More specifically, FIGS. 6A-6Fshow a method for establishing a test line or test plane 73 for thetesting of custom-fitted helmet 81. Test line 73 can be derived from acertified surface 77 rather than from a custom formed custom innersurface 82 of helmet 81. As described in greater detail below, theestablishment of test line 73 from certified surface 77 can be donegraphically or analytically with headform 66 of customer 20.

FIG. 6A shows a cross-sectional view of a test headform 74. Testheadform 74 can be a tangible physical object or an analytical orcomputer model that facilitates or allows for virtual testing ofphysical helmets or models of helmets. When test headform 74 is avirtual helmet or model, the test headform can include a CAD file, orother suitable computer file or program. Test headform 74, whetherphysical or virtual, can be appropriately sized, configured, or made toposses or correspond to any attribute or requirement of helmet safetystandard 71. Test headform 74 is configured to receive test helmets,such as helmet 78, and facilitates testing of the helmets to see if thehelmets satisfy the relevant safety standards, such as helmet safetystandard 71.

FIG. 6A further shows a helmet test line 73 formed on or associated withtest headform 74 as an example of how a helmet safety standard 71 mightbe used in testing a helmet or non-custom-fitted helmet 78. A helmet 78,which is to be tested against safety standard 71, can then be positionedon headform 74 and helmet test line 73 can then be transferred from theheadform to an outer surface or shell of a helmet 78 for testing. Duringtesting, test line 73 is used as a demarcation for indicating wherehelmet 78 can be subjected to impacts during testing. For example,tested helmet 78 may be subjected to impacts that are centered on orabove test line 73. Impacts used in the testing of helmet 78, or anyhelmet, occur at or above test line 73 at a top portion of a helmetbecause the top portion of the helmet is typically the most importantfor protecting user head 30, and impacts on a lower portion of helmet 78below test line 73 will normally cause the helmet to fail. Test line 73can be formed of any approved or certified shape in accordance withhelmet safety standard 71. As a non-limiting example, test line 73 isshown in FIGS. 6A-6F as a typical test line approved or used by theSnell Foundation.

As shown in FIG. 6A, test line 73 is transferred from test headform 74to outer surface 79 of helmet 78 so that a position or location of testline 73 is formed on, or associated with, helmet 78. The position oftest line 73 on helmet 78 is based on a fit between test headform 74 andhelmet 78. A relative position between test headform 74 and outersurface 79 of helmet 78 can be established by using basic plane,Frankfurt plane, or auricuolo-orbital plane 75 and a helmet positioningindex (HPI) relative to a point or plane of helmet 78, such as upperfaceport edge 76 at a front of the helmet. Basic plane 75 is ananatomical position of headform 74, a human skull, or customer head 30defined by a plane passing through a left orbitale (or the inferiormargin of the left orbit or eye-socket of the skull) and also passingthrough the left and right portions or the upper margins of each earcanal or external auditory meatus. The HPI defines a distance betweenbasic plane 75 of test headform 74 and a portion of helmet 78, such as afront portion of upper faceport edge 76 of helmet 78. HPI can includeany suitable distance based on the features and needs of a particularcustomer including distances in a range 35-65 millimeters (mm), 40-55mm, or about 47 mm.

Thus, in order to determine a location of test line 73 relative to outersurface 79 of helmet 78 and which portions of helmet 78 will besubjected to impact testing, the helmet is positioned with respect totest headform 74 so that an outer surface of test headform 74 “contacts”inner surface 80 of helmet 78. A front portion of a brow of customerhead 30 can be placed in contact with a brow portion of inner surface 80near an upper edge of the faceport. Helmet 78 can then be rotated sothat a top or crown portion of customer head 30 is placed in contactwith a crown portion of inner surface 80. Helmet 78 can be positionedwith respect to test headform 74 by placing a physical or tangiblehelmet on a physical or tangible headform, although more commonly agraphical or analytical comparison is made using computer generated 3Dimages of the helmet and test headform. With helmet 78 on test headform74, test line 73 is transferred from the headform to the helmet, therebydesignating the regions or portions of the helmet that can be impactedduring testing, for example on a test rig.

When a mass produced helmet of standardized sizing and standardizedinner surface is tested, such as helmet 78, the relative positions ofheadform 74 and any helmet 78 selected from the mass produced group willbe substantially identical or constant for all helmets in a groupbecause inner surface 80 for each helmet 78 is standardized and a shapeof headform 74 is constant. Accordingly, the relative position of testline 73 will also be constant for each and every helmet 78. A constantrelative position for test line 73 and helmet 78 allows for a smallrepresentative number of helmets to be destroyed in testing to certifythat all helmets 78 of a particular design satisfy the appropriatesafety standards.

To the contrary, custom-fitted helmet 81 includes a custom inner surface82 of protective base material 72, or an inner surface 85 of padding orinterface layer 84, such that each custom-fitted helmet 81 can have adifferent relative position with respect to test headform 74. Differentrelative positions between headform 74 and custom inner surface 82potentially result in a new position or location for each test line 73transferred from headform 74 to every custom-fitted helmet 81. Underconventional testing standards, each custom helmet would be required tobe produced in multiples so that a number of custom-fitted helmets 81could undergo destructive testing to ensure the design of a singlecustom-fitted helmet 81 worn by customer 20 satisfies the applicablesafety standards. Because producing multiples of each custom-fittedhelmet for destructive testing is not a commercially viable approach forproducing and selling custom-fitted helmets, non destructive testingincluding analytically or graphically comparing a custom-fitted helmet81 with a helmet safety standard 71 can be used. As a non-limitingexample, an alternative method for testing custom-fitted helmets 81 isshown in FIGS. 6B-6F and discussed below.

FIG. 6B shows a certified surface 77 for locating test line 73 on outersurface 83 of custom-fitted helmet 81 as part of a method for testingcustom-fitted helmets. Certified surface 77 is generated and approved aspart of helmet safety standard 71, and can be fixed with respect toouter surface 83 of custom-fitted helmet 81 to ensure a minimumthickness of protective base material 72 is used as part of thecustom-fitted helmet. While certified surface 77 can be coextensive withan inner surface of protective base material 72 or coextensive with aninner surface 82 of custom-fitted helmet 81, certified surface 77 canalso be different than inner surface 82 as discussed in greater detailwith respect to FIG. 6C.

FIG. 6B, in contrast to FIG. 6A, shows a cross sectional view of testheadform 74 within custom-fitted helmet 81 instead of non-custom fittedhelmet 78. FIG. 6B also shows, in addition to certified surface 77,inner surface 85 of padding or interface layer 84. Padding layer 84 canbe disposed between protective base material 72 and headform 74 or 3Dheadform 66. Padding layer 84 can be a comfort layer of foam, padding,or other suitable material that can be softer or more deformable thanprotective base material 72. Padding layer 84 can be of any thickness,and in an embodiment, has a thickness in a range of 0-20 mm, 1-10 mm, orabout 5 mm. Inner surface 85 is the surface of padding layer 84 that isclosest to customer head 30, 3D headform 66, or headform 74. Thus alocation, position, and contour of surface 85 of padding layer 84 can bedetermined and controlled by adding a distance or offset, representing athickness of padding layer 84, to the topography or contours of innersurface 82 of custom-fitted helmet 81. The distance or offset can beconstant for an entirety of padding layer 84 when a thickness of paddinglayer 84 is uniform and constant. Alternatively, the distance or offsetcan be variable or changing for at least a portion of padding layer 84when a thickness of padding layer 84 is non-uniform or variable.

Certified surface 77 can be generated or selected based on data fromnumerous customer heads 30, including 3D headforms 66. By taking a groupor set of head data for similarly sized heads, a certified surface 77can be generated that would accommodate each of the heads includedwithin the data set. Certified surface 77 does not need to existphysically, as a tangible structure within custom-fitted helmet 81 or aspart of a helmet base unit 86, but can exist mathematically,graphically, or as part of a model. In an embodiment, for example,certified surface 77 exists as part of a computer executable programsuch as a piece of CAD software, and can be used for defining orgenerating test line 73.

Advantageously, certified surface 77 can be used for positioningheadform 74 within custom-fitted helmet 81 or base unit 86 andtransferring test line 73 from the headform to outer surface 83 of thecustom-fitted helmet. In order to transfer test line 73 from headform 74to outer surface 83 of the custom-fitted helmet, the test headform canbe positioned in an uppermost and forwardmost position permitted bycertified surface 77 (or another relative position or offset defined bycertified surface 77 such as surface 85 of padding 84, which is referredto herein for convenience as the certified surface). As such, helmet 81can be positioned with respect to test headform 74 so that an outersurface of test headform 74 aligns or is coextensive with certifiedsurface 77. More specifically, a front portion of a brow of headform 74can be aligned with a brow portion of certified surface 77 near an upperedge of the faceport. Helmet 81 can then be rotated so that a top orcrown portion of headform 74 is aligned with a crown portion ofcertified surface 77, while also maintaining alignment with the browportions.

Helmet 81 can be positioned with respect to test headform 74 by placinga physical or tangible helmet on a physical or tangible headform,although more commonly a graphical or analytical comparison is madeusing computer generated 3D images of the helmet and test headform. Byaligning headform 74 toward the front and top portions of custom-fittedhelmet 81, a gap, offset, or some space can exist between a rear portionof headform 74 and a rear portion of certified surface 77, especiallyfor headforms of varying sizes including larger sizes. The gap can befilled with protective base material 72 by the formation of custom innersurface 82 based on a specific size or shape of an actual customer head30 or 3D headform 66, as discussed below in relation to FIG. 6C. Aftertest headform 74 is positioned within helmet 81, test line 73 is thentransferred from test headform 74 to outer surface 83 of custom fittedhelmet 81. In other words, a projection of test line or test plane 73can be extended outwards until it contacts or intersects with outersurface 83 of custom-fitted helmet 81 and an actual mark, or a set ofcoordinates or data is noted or saved relative to outer surface 83 toidentify which regions or portions of custom-fitted helmet 81 can besubsequently impacted during impact testing. In an embodiment, the testline 73 and the HPI are only used for certification purposes with thecertified surface and certified headform. The certified headform 74shows drawing a test line 73 can be done in a repeatable manner andtherefore any custom 3D headform 66 would follow the same establishedtest line 73 from an original certification.

FIG. 6C shows a cross-sectional view of 3D headform 66, rather than testheadform 74, disposed within custom-fitted helmet 81 comprising testline 73. FIG. 6C also shows how additional base material 72 can extendbeyond, or be added to, certified surface 77 to provide custom innersurface 82 that can include a topography that conforms to a length,width, and at least one contour of 3D headform 66 or customer head 30that is closer to 3D headform 66 than certified surface 77 is to the 3Dheadform. Custom inner surface 82 can also take into account, or includean offset for, padding or interface layer 84. Accordingly, a custominner surface 82 of custom-fitted helmet 81 can include surface 85 ofpadding layer 84 as shown in FIGS. 6C-6F. Advantageously, 3D headform 66can be positioned within custom-fitted helmet 81 and within certifiedsurface 77 in such a way as to optimize a fit of customer head 30 withincustom-fitted helmet 81 and to optimize a field of view (FOV) forcustomer 20. Additionally, 3D headform 66 can be positioned withincustom fitted helmet 81 by aligning or matching the brow portion ofheadform 66 with the brow portion of custom inner surface 82 of customfitted helmet 81 while also aligning crown portions of the 3D headformand custom inner surface.

By considering a position of an eye of customer 20 when positioning 3Dheadform 66 within custom fitted helmet 81, the FOV for customer 20 canbe increased. In an embodiment, the eye of customer 20 can by alignedwith a faceport of custom-fitted helmet 81 by adjusting a verticaloffset or distance between the eye of the customer and the upperfaceport edge 76, or the lower faceport edge, so that the edge of thefaceport does not obstruct the customer's vision. Optimal eye positionwithin the faceport can vary by application. For example, whenmaximizing customer FOV, a lower position of the faceport relative to acustomer's eye is desirable for upright street riding, while a higherposition of the faceport relative to a customer's eye is desirable foraggressive tucked race positions where a relative location of upperfaceport edge 76 is an important constraint for visibility.

Additionally, a distance between the eye of customer 20 can also bemoved closer to the faceport of custom-fitted helmet 81. In conventionalor stock helmet designs, a user's head is centered front to back withinthe helmet and can produce a significant offset between a front of thehelmet and the front of customer head 30. As a result of the offsetbetween the user's eye and the front of the helmet, edges of a helmetfaceport can obscure more of the user's FOV. On the other hand, byorienting customer head 30 the farthest forward permissible byapplicable safety standard 71, FOV can be improved for customer 20 byreducing an amount of obstruction created by faceport edges ofcustom-fitted helmet 81. Gains achieved by moving a customer's headfarther forward can also be greater for those customers that have headsthat are shorter front to back. Applicants have discovered that evensmall changes in distances between the eye of customer 20 and a front ofthe helmet, or vertical distances between the customer's eye and theupper and lower edges of the helmet faceport, can have significanteffects on the area of the customer's FOV.

Once 3D headform 66 is properly aligned within custom-fitted helmet 81,unwanted gaps or spaces between certified surface 77 and the 3D headformcan be identified and eliminated by providing protective base material72 (and optionally padding 84) to fill the gap between certified surface77 and customer 3D headform 66. While providing protective base material72 within the gap between certified surface 77 and 3D headform 66 can bethought of as “filling” the gaps, in some embodiments, gaps will notphysically exist between a physically constructed custom inner surface82 and customer head 30. For example, an analytical or computationalcomparison can be made physically, graphically, analytically, with CADsoftware, or with other suitable program before forming custom innersurface 82 so that the custom inner surface can be formed, such as bybeing cut, from helmet base unit 86 to conform to the length, width, andat least one contour of the customer's head without an unwanted gapexisting between certified surface 77 and 3D headform 66 or customerhead 30.

By forming custom inner surface 82 with additional base material 72between 3D headform 66 and certified surface 77, custom-fitted helmet 81may be more comfortable than a standardized or certified helmet that hasbase material 72 only extending to certified surface 77. Also, thecustom-fitted helmet 81 will satisfy safety standard 71, or can beeffectively tested using the same test line 73 for an entire class ofcustom-fitted helmets 81 instead of requiring destructive testing foreach new custom-fitted helmet 81 that is made. Stated another way, anycustom-fitted helmet 81 that includes a custom inner surface 82 that isoutside or offset from certified surface 77 by having a minimum distancebetween outer surface 83 and custom inner surface 82 that is greaterthan a minimum distance between outer surface 83 and certified surface77, will also satisfy safety standard 71 or can be effectively testedusing the same test line 73. Stated yet another way, any custom-fittedhelmet 81 that includes a custom inner surface 82 that does not placecustomer head 30 or 3D headform 66 in such a way as to extend through orbeyond certified surface 77 toward outer surface 83, will also satisfysafety standard 71, or can be effectively tested using the same testline 73.

As such, in an embodiment, a person having ordinary skill in therelevant art will understand that certified surface 77 is a baselinesurface indicating that any other custom inner surface 82 positionoutside (or more distant from outer surface 83 that certified surface77) will produce helmets that meet the helmet safety standard, or can beeffectively tested using the same test line 73. Accordingly,custom-fitted helmets 81 comprising custom inner surfaces 82 can becertified by measuring against certified surface 77 and testing againsttest line 73 without each custom-fitted helmet needing to undergodestructive testing like a non-custom fitted helmet 78, as describedabove. Therefore, use of test headform 74 for the creation of a uniformtest standard such as test line 73 relative to a certified surface 77for a range or class of custom-fitted helmets 81 can remove the economicburden produced by destructive testing of each custom-fitted helmet 81,making large scale production of safety certified custom-fitted helmetspractical.

As a non-limiting example, Applicant has worked with responsible partiesat the Snell foundation and established an acceptable working method forconsistently positioning ISO headforms with respect to certifiedsurfaces 77 and within custom-fitted helmets 81, or models of the same,in such a way that test lines 73 will be constant or fixed with respectto various custom-fitted helmets, thereby allowing a single test tocertify the safety of a number of similar helmets all having differentinner surfaces, without the waste of destroying custom made helmets.FIGS. 6D-6F, described in greater detail below, illustrate anon-limiting example of how Applicant has worked with the SnellFoundation to produce a procedure for testing custom-fitted helmets 81.

FIG. 6D shows a medium ISO test headform 74 a disposed within acustom-fitted helmet 81 that comprises a certified surface 77 for amedium sized head or headform. However, because customer heads haveunique topographies including differing lengths, widths, and contoursfrom each other, the generic shape and contour of test headform 74 a isdifferent from custom inner surface 82. Custom inner surface 82 extendsout from certified surface 77, or stated another way, includes an actualdimension DA greater than minimum dimension DM associated with certifiedsurface 77. As such, custom inner surface 82 is only partially incontact with headform 74 a and is not properly situated withincustom-fitted helmet 81 as headform 66 or customer head 30 would be.FIG. 6D shows headform 74 a includes basic plane 75 a that is rotatedwith respect to nominal basic plane 75 that is offset from the top ofthe helmet faceport by the HPI. FIG. 6D also shows that a top crownportion of headform 74 a is not in contact, or aligned, with a top crownportion of custom inner surface 82. Instead, the top crown portion ofheadform 74 a is offset from, and has a gap with respect to, the topcrown portion of custom inner surface 82. Both the rotation and the poorfit between headform 74 a and custom inner surface 82 can provideproblems for using the headform for testing.

Similarly, FIG. 6E shows an alternative configuration in which custominner surface 82 provides a problem for using medium ISO test headform74 a for testing. In FIG. 6E, medium ISO test headform 74 a is disposedwithin a custom-fitted helmet 81 that comprises the custom inner surface82 shown in FIG. 6D. However, instead of having basic plane 75 a ofheadform 74 a different from the nominal basic plane 75, FIG. 6E showsthe basic plane 75 a of headform 74 a aligned with the nominal basicplane and properly offset from upper faceport edge 76 according to theHPI. However, because the generic shape and contour of test headform 74a is different from custom inner surface 82, headform 74 a is shownextending beyond inner surface 82. Practically speaking, by allowingheadform 74 a to extend beyond inner surface 82, the model presents asituation in which a customer head 30 would be occupying space occupiedby protective base material 72. As such, the configuration shown in FIG.6E is also impractical for impact testing custom-fitted helmet 81because misalignments between medium headform 74 a and inner surface 82of custom-fitted helmet 81 result from the unique length, width, andcontours of an actual customer head 30 or headform 66 used for theformation of custom inner surface 82. Therefore, the misalignmentsbetween medium headform 74 a and inner surface 82 of custom-fittedhelmet 81 shown in FIGS. 6D and 6E suggest a medium ISO test headform 74a is too large for at least some custom-fitted helmets 81 comprising acertified surface 77 designed for medium head sizes.

FIG. 6F shows an embodiment in which a smaller ISO headform such assmall ISO test headform 74 b, rather than a medium ISO test headform 74a, is disposed within a custom-fitted helmet 81 for the testing of thecustom-fitted helmet comprising a certified surface 77 for a mediumsized head or headform. By using small ISO test headform 74 b, headform74 b can fully contact all portions of custom inner surface 82 and beproperly situated within custom-fitted helmet 81 as headform 66 orcustomer head 30 would be. Additionally, by using small ISO testheadform 74 b the basic plane of headform 74 b can also be aligned withthe nominal basic plane and properly offset from upper faceport edge 76according to the HPI. Thus, the smaller volume of headform 74 b allowsfor more flexibility in fitting the headform within an area of custominner surface 82 that is less than an area of certified surface 77.Additionally, in order for small ISO headform 74 a to provide acceptabletesting results for a medium sized certified surface, the small ISOheadform 74 a can be weighted to match, and to respond during testing,as medium sized ISO headform 74 b.

The exemplary embodiment of FIG. 6E shows test line 73 b associated withheadform 74 b and aligning on outer surface 83 of custom-fitted helmet81 at a position or location different from test line 73. However, thepresence of differently positioned test lines resulting from differentISO headforms can be ignored for the purposes of establishing the impactline so long as the ISO headform being used is properly aligned withhelmet and 81 and within, or does not pass through) certified surface77. Thus, the established test line 73 is used for impact testing whileusing the properly weighted small ISO headform 74 b. While testheadforms 74 a and 74 b have been referred to as medium and small sizedheadforms respectively, a person of ordinary skill of the art willunderstand that any first and second headforms of differing sizes couldbe used and be equally applicable to the foregoing example.

Furthermore, as has been discussed in relation to FIGS. 6B-6F, differentISO headforms can be used for establishing a test line and forconducting impact testing, which is in contrast to conventional testingin which only a single ISO headform has been used for both establishingthe test line and the conducting the impact testing. As discussed above,a first ISO headform, such as headform 74 shown in FIG. 6B, can be usedfor establishing the location and position of test line 73 with respectto certified surface 77. A second ISO headform, such as headform 74 bshown in FIG. 6F, can be used for conducting the impact testing ofcustom-fitted helmet 81.

After determining what inner surface 82 of custom-fitted helmet 81 willbe, based for example on customer head data and helmet safety standard71, inner surface 82 can be formed. As indicated above with reference toFIG. 4C, and shown in FIGS. 7A-7B, a helmet base unit 86 can be used toform custom-fitted helmet 81, including inner surface 82, which iscustomized to the topography or the length, width, and at least onecontour of customer head 30 or 3D headform 66. Helmet base unit 86 canbe made of impact protective material that is easily removable orcuttable to conform to customer head 30, headform 66, or both. Helmetbase unit 86 can be formed of an energy attenuating material such asEPS, EPP, plastic, foam, PET, VN, PU, EVA, cork, rubber, orbathane,Zorbium, EPLA, brock foam, or other suitable material or blendedcombination or hybrid of material.

Helmet base unit 86 includes an outer surface 83, a custom inner surface82, and protective base material 72 between the outer and inner surfacethat will accommodate both helmet safety standard 71 and 3D headform 66.Thus, helmet base unit 86 can be of any size and shape before beingcustomized to fit customer head 30. Customization of base unit 86 forthe formation of custom-fitted helmet 81 can be by an additive orsubtractive process. In fact, helmet base unit helmet 86 may, inparticular customizable embodiments, be initially formed as a block ofprotective material that is entirely trimmed down to form the customizedhelmet shape and design that conforms to customer head 30 according to3D headform 66. Thus, helmet base unit 86 can be initially formed as anon-descript block base unit or as a helmet-shaped base unit thatincludes material inside and outside of the final customized helmet,which will be customized through removing excess material from thehelmet base unit. Alternatively, helmet base unit 86 can be ahelmet-shaped base unit that includes material inside that will becustomized through removing excess material and an outer surface 83 thatdoes not require customization. An example of a helmet base unit 86 thatincludes an outer surface 83 that does not require customization and acustom inner surface 82 that leaves material inside the helmet base unitthat will be customized is illustrated in FIG. 7B. Additionally,formation of custom-fitted helmet 81 can be formed by an additiveprocess, such as 3D printing, to build-up outer surface 83 and custominner surface 82.

However, in order to minimize an amount of protective base material 72that can be removed to reduce or minimize weight and size ofcustom-fitted helmet 81, helmet base unit 86 can be formed such thatouter surface 83 is formed with a shape, form, and contour equal to afinal shape, form, and contour of the final custom-fitted helmet 81.Similarly, helmet base unit 86 can be formed such that custom innersurface 82 includes a shape, form, and contour that approximates or issomewhat larger than the final shape, form, and contour of custom innersurface 82 of completed custom-fitted helmet 81. Thus, by preparing ahelmet base unit 86 that approximates a final shape and design ofcustom-fitted helmet 81, the amount of protective base material 72 thatis removed for customizing custom inner surface 82 is reduced.

In order to ensure that helmet base unit 86 approximates a final shapeand design of custom-fitted helmet 81, for a plurality of customers ofdifferent head shapes and sizes, a number of helmet base unit modelsincluding sizes ranging from a small size to a large size can beprovided. Thus, helmet base unit 86 can be selected from a number ofhelmet base unit models to have the smallest possible helmet size,thereby minimizing helmet weight and size while still allowing customer20 to have a custom-fitted helmet 81 with a thickness greater than orequal to minimum dimension DM of helmet safety standard 71 between asurface of customer head 30 and outer surface 83 of custom-fitted helmet81. Dimensions of helmet base unit 86 can then be altered to generate acomputerized helmet model 88. Computerized helmet model 88 includes atleast a digital data set indicative of a portion of a helmet. In someembodiments, computerized helmet model 88 includes a model of at leastcustom inner surface 82 of custom-fitted helmet 81. Additionally, and asdiscussed more fully below, in some cases all of the dimensions of thecustom-fitted helmet 81 may be calculated by a processor associated withthe database 24. In a particular embodiment, a graphical comparison canbe made visually or analytically between headform 66, minimum dimensionsDM of helmet safety standard 71, and helmet base unit 86 to visuallydetermine if any minimum dimensions DM are not met and extend into aspace occupied by headform 66 or extend beyond helmet base unit 86. If aportion of headform 66 does extend into at least a portion of minimumdimensions DM for helmet base unit 86, a larger or different helmet baseunit model is chosen.

As shown in FIG. 7C, after obtaining head data for customer head 30 andoptionally generating 3D headform 66, the 3D headform or head data iscompared to helmet safety standard 71 to form custom-fitted helmet 81based on the 3D headform or head data such that the custom-fitted helmetsatisfies the safety standard 71 and custom inner surface 82 comprises atopography that conforms to the length, width, and at least one contourof the customer head. Forming of custom-fitted helmet 81 can be at asecond location, different from the first location where the head datafor customer head 30 is obtained. As indicated above, custom-fittedhelmet 81 can be formed by an additive or subtractive process. Forsubtractive processes in which material is removed to form custom innersurface 82, an appropriate helmet base unit 86 is determined, asdescribed above, that will allow for the minimum dimensions DM requiredto satisfy helmet safety standard 71, while minimizing or reducingadditional helmet thickness and weight not required for comfort. In aparticular, non-limiting embodiment, helmet base unit 86 is selected tohave a size from which about 6 mm-8 mm of material is removed to formcustom inner surface 82 of custom-fitted helmet 81. Accordingly, a headcavity 90 of helmet base unit 86 is approximately 20% smaller than headcavity 92 of custom-fitted helmet 81. Stated another way, head cavity 90of helmet base unit 86 includes a size or volume approximately 81% of asize or volume of head cavity 92. However, various other standardinitial thicknesses, volumes, and sizes may be used and could be morepractical depending upon a number of factors, including a style ofhelmet, a type of impact protection provided, a type of material used,or a combination of factors.

Depending upon what type of material is used for protective basematerial 72 of helmet base unit 86, any of several different methods maybe used to remove excess protective base material 72 from the helmetbase unit. Those of ordinary skill in the art will readily understand ordetermine without undo experimentation which method of removingprotective base material 72 is best based on a composition of theprotective base material. FIG. 7C shows use of a CNC machine or routingmachine 94 including cutting blade 96 is a method that works well forremoval of excess protective base material 72 comprising EPS. To thecontrary, use of a CNC machine can be less effective for EPP than withEPS because EPP tends to melt or deform during removal of protectivebase material 72 with CNC machine 94. Rotating cutting blade 96 is usedto carve away excess protective base material 72 from helmet base unit86 so that custom inner surface 82 comprises a topography that conformsto customer head 30, 3D headform 66, or both. An appropriate jig 98 canbe used to hold helmet base unit 86 during removal of a portion ofprotective base material 72. Jig 98 can include any structure configuredto prevent undesired movement of base unit 86 during removal ofprotective base material 72. As shown in FIG. 7C, jig 98 can compriseinterlocking members 100 that interface with jig 98 and are configuredto interlock with helmet base unit 86. Helmet base unit 86 can includeposts or protrusions 102 formed as part of the helmet base unit andconfigured to interlock with jig 98. Posts 102 can be of any shape andcan be built-up on helmet base unit 86, or alternatively, can be formedas openings or holes that act as receptors for receiving interlockingmembers 100 of jig 98. When posts 102 are formed as protrusionsextending away from outer surface 83, the posts may be removed or may becovered by other coverings on the finished custom-fitted helmet 81 afterhaving been used to interlock with jig 98. Alternatively, the jig may beformed to interlock or interface with a permanent feature or shape onthe helmet base unit that is not removed by subsequent processing.

Importantly, customization of custom inner surface 82 to include atopography that conforms to the length, width, and at least one contourof the customer head 30 can be done with any shape or style of helmet.Other non-limiting examples for other helmet types are shown in FIGS.8A-9D. In particular embodiments, excess protective base material 72,including posts 102, can be removed after helmet base unit 86 has beencoated or inserted into an outer shell such as a decorative outer shell.Alternatively, excess protective base material 72, including posts 102,can be removed before helmet base unit 86 has been coated or insertedinto an outer shell, or removed without subsequent use of an outershell.

FIG. 7D shows custom-fitted helmet 81 including a finished custom innersurface 82 comprising a topography that comprises a length, width, andat least one contour of customer head 30. Custom-fitted helmet 81 ofFIG. 7D differs from helmet base unit 86 shown in FIG. 7A in that athickness or an actual dimension DA between outer surface 83 and custominner surface 82 of custom-fitted helmet 81 in FIG. 7D is less than athickness or an actual dimension DA between outer surface 83 and custominner surface 82 of helmet base unit 86 shown in FIG. 7A. Stated anotherway, the actual dimension DA between outer surface 83 and custom innersurface 82 of helmet base unit 86 in FIG. 7A is greater than thethickness or actual dimension DA between outer surface 83 and custominner surface 82 of custom-fitted helmet 81 in FIG. 7D.

The process of forming a customized custom inner surface 82 forcustom-fitted helmet 81 is applicable not only to a tangible helmet baseunit 86, but is likewise applicable to computerized helmet models 88. Inan embodiment, a computerized helmet model 88 can be a virtual orgraphical model that comprises dimensions, forms, shapes, contours, andcharacteristics of a final helmet that include an outer surface 83 andalso satisfies helmet safety standard 71. In other words, computerizedhelmet model 88 can be a virtual representation of a tangible orphysical helmet base unit 86. A portion of computerized helmet model 88can be formed or modified based on head data of customer head 30 orbased on 3D headform 66. Specifically, computerized helmet model 88 canbe formed or modified such that a custom inner surface 82 comprises atopography that conforms to a length, width, and at least one contour ofcustomer head 30, 3D headform 66, or both. Computerized helmet model 88can be used as a starting point for customization of a custom innersurface 82 by modifying helmet base unit 86 to form custom-fitted helmet81, as indicated above with respect to FIGS. 7A-7D. Alternatively,computerized helmet model 88 can be used to form custom inner surface 82by an additive process. Custom inner surface 82 of custom-fitted helmet81 can be created, for example, using a 3D printer, a customer headdata-specific mold, or other one-time or one-off manufacturing method,including, by way of example and not by limitation, physical castingwith plaster, Room Temperature Vulcanizing (RTV), or casting or moldingwith Urethane, Clay, Wax, Paper Mache or other materials used forcasting, molding, or copy milling.

FIG. 8A shows a cross sectional view of custom-fitted helmet 81 formedas a multi-layer helmet 106 that includes an outer layer or first layer108 and an inner layer or second layer 110. Outer layer 108 includesouter surface 83 and inner layer 110 includes custom inner surface 82.While multi-layer helmet 106 is shown with two distinct layers, namelyouter layer 108 and inner layer 110, any number of a layers can be used,including any number of layers disposed between the custom inner surface82 and outer surface 83.

Inner layer 110 can be formed of a material that is identical, similar,or different from outer layer 108. Inner layer 110 can be coupled toouter layer 108 by chemical bonds, mechanical bonds, or both, and can becoupled using an adhesive, a bonding agent, or friction. Outer layer 108can be a standard helmet shell of impact protective material similar tohelmet base unit 86 that includes a protective base material 72 andfurther comprises an outer surface 83. An inner surface of outer layer108 is not configured to be in contact with user head 30, but instead isconfigured to be in contact with, or coupled to, one or more innerlayers 110.

Custom inner surface 82 of inner layer 110 can be formed by an additiveor subtractive process. Inner layer 110 can be applied as a separatelymanufactured insert from outer layer 108, in which inner layer 110 isformed by spraying or as another molded material added to outer layer108 during manufacturing, or later, or in any other manner known in theart. Portions of one or more inner layers 110 can be sculpted orotherwise removed as part of a subtractive process such that custominner surface 82 conforms to head data for customer head 30 or 3Dheadform 66. A final custom inner surface 82 can be formed either beforeinner layer 110 is added to outer layer 108, or after inner layer 110 isadded to outer layer 108. Inner layer 110 includes custom inner surface82 that comprises a topography that conforms to the length, width, andat least one contour of customer head 30. Custom inner surface 82 can bein direct contact with customer head 30 or customer hair 32.Alternatively, custom inner surface 82 can be coupled or in contact withone or more padding or interface layers 84 that are in direct contactwith customer head 30 or customer hair 32. Padding layer 84 can bedisposed over custom inner surface 82 of custom-fitted helmet 81, as alayer comprising a uniform thickness. Alternatively, padding layer 84can be formed as a layer comprising a variable or differing thickness inwhich various portions of the padded layer can be formed with differentamounts of padding or cushioning relative to specific portions ofcustomer head 30 or custom-fitted helmet 81. However, when padding layer84 is formed with variable thickness the different amounts of paddingneed not be used to account for differences between a topography of aninner surface of a generic helmet and a topography of the customer'shead as has been conventionally done with generic one-size-fits-manyhelmets.

In particular embodiments, inner layer 110 can be formed of a materialthat is more easily removable or cuttable than outer layer 108.Depending upon the manufacturing processes used for forming custom innersurface 82, inner layer 110 can be formed of any suitable protectivehelmet material known in the art, including EPS, various foams, EPP,Plastic, expanded polyethylene, VN, PU, EVA, Cork, Rubber, Sorbathane,Zorbium, EPLA, brock foam, or combinations of any of the above.

For subtractive methods of forming custom inner surface 82 of innerlayer 110, any of several different methods may be used to remove excessmaterial from the inner layer depending upon the protective materialused in forming helmet base unit 86. Those of ordinary skill in the artwill readily understand or determine without undo experimentation basedon the protective material used in helmet base unit 86, which method ofremoval is best for protective base material 72. One method that workswell with removal of excess EPS is routing or CNC machining, asdescribed above with respect to FIG. 7C. By forming multi-layer helmet106 with outer layer 108 of impact protective material, and disposinginner layer 110 adjacent to the inner layer, a better fitting and betterperforming helmet can be achieved that is unique to each customer 20.

In an embodiment, as indicated above, an additional inner layer can beapplied as an insert that is separately manufactured from an outerlayer. The inner layer can, for example, be formed by spraying, or byany other manner known in the art. The inner layer insert includes innerlayer 110, as shown and described with respect to FIG. 8A. Additionally,inclusion of an inner layer as part of a method for providing acustom-fitted helmet can be applicable to all helmet types, includingfull face helmets for various sports, as mentioned above, includingmotorsports and powersports, as is also indicated below, for example,with respect to FIGS. 9A and 9B. As a non-limiting example, acustom-fitted in-molded polycarbonate (PC)/EPS liner can be insertedinto a stock helmet to replace an existing stock helmet liner or stockcomfort padding layer. In such a case, a manufacturer, technician, oreven customer 20 removes the existing comfort padding or liner from thestock helmet and places the custom manufactured insert (such as thecustom-fitted in-molded PC/EPS liner) into the stock helmet. However, ascustomers are not typically experts of fitting helmets, in someembodiments, fitting by a manufacturer or trained technician ispreferable. The custom manufactured insert is installed within the stockhelmet to provide a customized version of the stock helmet. The custommanufactured insert can be installed into the stock helmet usingexisting mechanical fasters. For example, the custom manufactured insertcan be installed in the stock helmet using the same padding snaps thatwere used to couple the stock comfort padding or liner to an outer layerof the stock helmet. Advantageously, the custom manufactured insert canfurther comprise comfort padding, which can be thinner than the existingcomfort padding.

FIG. 8B shows a perspective view of multi-layer helmet 106. Whilemulti-layer helmet 106 can be formed as any type of helmet, FIGS. 8A and8B show a particular non-limiting embodiment for a bicycle helmet. Forany of the embodiments disclosed or contemplated herein, additionalcustomizing may be done to custom-fitted helmet 81, including forming acustomized helmet protective material 112 as part of the custom-fittedhelmet. For example, FIG. 8B shows protective material 112 formed as aprotective, functional, or decorative outer shell formed over outersurface 83 of outer layer 108. Additional customization can furtherinclude padding layer 84 added to custom inner surface 82, strapsincluding chin straps and neck straps coupled to custom-fitted helmet81, as well as colors and stylistic features. Thus, those of ordinaryskill in the art will readily understand from this disclosure thatmultiple levels of customization are now possible and practical in abusiness environment for the customization of custom-fitted helmets 81.

FIG. 9A shows another embodiment of a custom-fitted helmet 81, in whichan inner layer 114 comprising additional material can be added to outerlayer 108, as described above with respect to FIGS. 8A and 8B. Innerlayer 114 differs from inner layer 110 in that instead of being a beingcomposed of a single monolithic piece like inner layer 110, inner layer114 comprises a plurality of segments 116. Segments 116 can be aflexible, semi-flexible, extendable, or reconfigurable component thatare permanently joined, temporarily joined, or separate from one anotherand separately attached to outer layer 108. Thus, segments 116 areformed in one or more contiguous or disjointed parts and assembled asone piece or as separate pieces to outer layer 108. FIG. 9A shows a gapor channel 118 is formed or exists between segments 116, such that thesegments are not directly connected or do not directly contact oneanother.

FIG. 9B shows another embodiment in which segments 116 are outside ofouter layer 108 and are connected by joining members 120. Joining member120 can be formed of aluminum, nylon, plastic, or other flexiblematerial, and extend between segments 116 to provide a fixed or variablespacing, such as a gap or channel, between the segments. Joining members120 can be partially exposed from segments 116 and partially embeddedwithin the segments. Single or individual joining member can be coupledto, or extend through, multiple segments 116. In an embodiment, aplurality of segments 116, including a totality of segments 116, isconnected with a single joining member 120 that includes separate spokeportions extending radially from a central area.

As illustrated in both FIGS. 9A and 9B, segments 116 can be manufacturedoutside of outer layer 108 and then assembled into a custom-fittedhelmet 81, such as by being coupled to outer layer 108. Accordingly,segments 116 can be arranged to form inner layer 114 that comprisescustom inner surface 82 and further comprises a topography that conformsto the length, width, and at least one contour of customer head 30 orheadform 66.

FIG. 9B further shows segments 116 of inner layer 110 can be arranged orformed in a flat or planar array or a substantially flat or planar arraywith a number of segments 116 disposed around a central or crown segment117 and attached by joining members 120. Similarly, segments 116 mayalso be formed in an array that is not completely flat or planar, but issufficiently flat or planar to allow cutting blade 96 of CNC machine 94or other sculpting tool to access portions of segments 116 necessary forforming custom inner surface 82. Advantageously, cutting blade 96 of CNCmachine 94, or other sculpting tool, can be used to form, sculpt, orpattern custom inner surface 82 of segments 116 that would beinaccessible if not in a flattened form. For example, while segments 116are disposed in the flat arrangement, removal of material from segments116 in hard to reach places, such as at a portion of a helmet followinga contour of a customer's occipital curve, are made accessible totraditional CNC or sculpting machines. Traditional CNC machines cannotcreate a helmet recurve to match a customer's occipital curve on a rigidhelmet base unit because the cutting portion of the CNC machine cannotchange an angle of the cutting blade from a strict vertical position toa required angled position. By placing segments 116 in a substantiallyflat or planar position, a topography of custom inner surface 82 can beformed to match contours of customer head 30 with only vertical accessto segments 116. Thus, a custom-fitted helmet 81 can include a recurveformed of a rigid impact protective material such as EPS or EPP or of asemi-rigid impact protective material such as vinyl nitrile (VN), VNfoam, or other suitable foam or similar material. After completion ofcustom inner surface 82 by removal of material by a CNC machinecomprising a vertical blade, the flat or substantially flat array ofsegments 116 can then be formed as part of a custom-fitted helmet 81,such as by being inserted into, and coupled to, outer layer 108.

FIGS. 10A and 10B show additional exemplary embodiments of custom-fittedhelmets 81, in which portions of the helmets other than just a top innerportion near a crown of user head 30 is customized. For example, bygathering data relating to placement and shape of one or more of a brow,nose, ears, eyes, mouth, cheek, chin, or neck of customer 20, and byknowing how the particular helmet will be used, other customizations maybe made. For example, other helmet components that may contact the faceor head 30 of customer 20 can be adjusted to comprise a surface ortopography that matches a shape, size, or contour, of any feature ofcustomer 20. Additionally, a customer's FOV can be increased byoptimizing a position of the customer's eyes relative to a faceportopening or eye openings within the helmet.

Specifically, FIG. 10A shows custom-fitted football helmet 124, and FIG.10B shows custom-fitted motorcycle helmet 128. Because custom-fittedfootball helmet 124 and custom-fitted motorcycle helmet 128 includehelmet portions, such as the side panels or face guard area thatsurround sides of the face, cheeks, or both of customer 20, portions ofhelmets 124 and 128, such as custom panels, can be formed to conform tothe face, cheeks, or both of customer 30 for a more comfortable andbetter fitting helmet. In biking, for example, helmets are worndifferently if the biker is touring, staged, or racing position. Forbike racing, the helmet can be adapted and conformed to allow thecustomer to be in a stage or race position without the helmetinterfering with the customer's sight based on the particular customer'seye position. Relatedly, a customized neck component for a hockey helmetcomprising an inner surface shaped to conform to the customer's neck canalso be formed.

It is to be understood that the disclosure is not limited to the exactdetails of construction, operation, exact materials, or embodimentsshown and described, as obvious modifications and equivalents will beapparent to one skilled in the art; for example, the photographs may bedigital photographs or paper based photographs that may then be scannedinto digital form. While the specific embodiments have been illustratedand described, numerous modifications come to mind without significantlydeparting from the spirit of the disclosure.

As used herein, the terms “component,” “system” and the like in relationto discussions about computer-related processes and systems are intendedto refer to a computer-related entity, either hardware, a combination ofhardware and software, software, or software in execution. For example,a component may be, but is not limited to being, a process running on aprocessor, a processor, an object, an instance, an executable, a threadof execution, a program, a computer, or both. By way of illustration,both an application running on a computer and the computer can be acomponent. One or more components may reside within a process, a threadof execution, or both, and a component may be localized on one computerand/or distributed between two or more computers.

Furthermore, all or portions of the computer-related processes andsystems can be implemented as a method, apparatus or article ofmanufacture using standard programming and/or engineering techniques toproduce software, firmware, hardware, or any combination thereof tocontrol a computer to implement the disclosed innovation. The term“article of manufacture” as used herein is intended to encompass acomputer program accessible from any computer-readable device or media.For example, computer readable media can include but are not limited tomagnetic storage devices (e.g., hard disk, floppy disk, magnetic strips. . . ), optical disks (e.g., compact disk (CD), digital versatile disk(DVD) . . . ), smart cards, and flash memory devices (e.g., card, stick,key drive . . . ). Additionally, it should be appreciated that a carrierwave can be employed to carry computer-readable electronic data such asthose used in transmitting and receiving electronic mail or in accessinga network such as the Internet or a local area network (LAN). Of course,those skilled in the art will recognize many modifications may be madeto this configuration without departing from the scope or spirit of theclaimed subject matter.

Where the above examples, embodiments and implementations referenceexamples, it should be understood by those of ordinary skill in the artthat other helmet and manufacturing devices and examples could beintermixed or substituted with those provided. In places where thedescription above refers to particular embodiments of helmets andcustomization methods, it should be readily apparent that a number ofmodifications may be made without departing from the spirit thereof andthat these embodiments and implementations may be applied to other tohelmet customization technologies as well. Accordingly, the disclosedsubject matter is intended to embrace all such alterations,modifications and variations that fall within the spirit and scope ofthe disclosure and the knowledge of one of ordinary skill in the art.

The invention claimed is:
 1. A multi-step method of designing an energyattenuation layer for installation within a protective sports helmet,the multi-step method comprising the steps of: obtaining head data froma player's head; processing the head data to create a computerized modelof the player's head; providing a computerized reference surface;comparing the computerized model of the player's head with thecomputerized reference surface to assess whether the computerized modelof the player's head extends through the computerized reference surface;and when said computerized model of the player's head does not extendthrough the computerized reference surface, creating a digital model ofan energy attenuation layer based in part upon said computerized modelof the player's head.
 2. The multi-step method of claim 1, wherein thestep of obtaining head data from the player further includes: providinga deformable interface member that has a thickness; placing thedeformable interface member over an extent of the player's head; andcapturing images of the deformable interface member that is positionedover the extent of the player's head.
 3. The multi-step method of claim1, wherein the step of obtaining head data from the player includesusing a software program installed on a non-contact scanning device thatguides a person through a process of collecting the head data from theplayer.
 4. The multi-step method of claim 1, wherein the step ofobtaining head data from the player includes using a mechanicalmeasurement device that includes contact probes that make contact withthe player's head.
 5. The multi-step method of claim 1, furthercomprising a step of providing a plurality of helmet models, and whereinthe provided computerized reference surface is associated with a helmetmodel selected from the plurality of helmet models.
 6. The multi-stepmethod of claim 5, further comprising the steps of: selecting a physicalhelmet shell that corresponds to the selected helmet model; andinstalling a physical energy attenuation layer in the physical helmetshell, wherein the physical energy attenuation layer corresponds to thedigital model of the energy attenuation layer.
 7. The multi-step methodof claim 5, further comprising a step of selecting another helmet modelfrom the plurality of helmet models that is larger than the previouslyselected helmet model when said computerized model of the player's headextends through the computerized reference surface.
 8. The multi-stepmethod of claim 1, further comprising a step of using a threedimensional printer to form a physical energy attenuation layer from thedigital model of the energy attenuation layer.
 9. The multi-step methodof claim 1, further comprising a step of forming a physical energyattenuation layer from a plurality of separately formed reconfigurablepadding components based upon the digital model of the energyattenuation layer.
 10. The multi-step method of claim 1, wherein thedigital model of the energy attenuation layer includes an inner surfacewith a topography that conforms to a surface that is derived from thecomputerized model of the player's head.
 11. The multi-step method ofclaim 1, further comprising the step of positioning the computerizedmodel of the player's head in the computerized reference surface byaligning a front portion of a brow of the computerized model of theplayer's head with a pre-identified location.
 12. The multi-step methodof claim 11, wherein the pre-identified location is positioned near anupper edge of an opening formed in a helmet model that is associatedwith the provided computerized reference surface.
 13. A multi-stepmethod of manufacturing a protective sports helmet to be worn by aplayer while playing a sports activity, the multi-step method comprisingthe steps of: obtaining head data from a player's head using a scanningdevice; providing a plurality of helmet models, wherein each helmetmodel has both a size and a reference surface; selecting one of thehelmet models from the plurality of helmet models; comparing theobtained head data against the reference surface of the selected helmetmodel to assess whether the obtained head data extends through thereference surface; and when the obtained head data does not extendthrough the reference surface, obtaining a physical helmet shell that(i) corresponds to the selected helmet model and (ii) is configured toreceive a physical energy attenuation layer.
 14. The multi-step methodof claim 13, wherein the scanning device includes a software programthat guides a person through a process of collecting images of theplayer's head.
 15. The multi-step method of claim 13, wherein thescanning device is a mechanical measurement device that includes contactprobes.
 16. The multi-step method of claim 13, further comprising thestep of (i) processing the head data to create a computerized model ofthe player's head, and (ii) creating a digital energy attenuation layerbased in part upon the computerized model of the player's head.
 17. Themulti-step method of claim 16, wherein the digital energy attenuationlayer includes an inner surface with a topography that conforms to asurface that is derived from the computerized model of the player'shead.
 18. The multi-step method of claim 16, further comprising the stepof using a three dimensional printer to form the physical energyattenuation layer from the digital energy attenuation layer.
 19. Themulti-step method of claim 16, further comprising the step of formingthe physical energy attenuation layer from a plurality of separatelyformed and reconfigurable padding components based upon the digitalenergy attenuation layer.
 20. The multi-step method of claim 13, furthercomprising the step of selecting another helmet model from the pluralityof helmet models that is larger than the previously selected helmetmodel when the obtained head data extends through the reference surfaceof the selected helmet model.
 21. The multi-step method of claim 13,wherein the reference surface is a certified surface of a computerizedsafety standard.
 22. A protective sports helmet to be worn by a playerwhile playing a sports activity, the protective sports helmetcomprising: a physical helmet shell configured to receive a head of theplayer; and an energy attenuation layer removably positioned within thephysical helmet shell, wherein the energy attenuation layer includes:(i) an outer surface that resides adjacent to an inner surface of theshell, (ii) an inner surface that resides adjacent to an outer surfaceof a player's head when the protective sports helmet is worn by theplayer, and (iii) a thickness that is defined between: (a) the outersurface of the energy attenuation layer and (b) the inner surface of theenergy attenuation layer, and wherein at least one extent of thethickness of the energy attenuation layer is equal to or greater than acorresponding predetermined minimum dimension that extends between: (c)a point on the outer surface of the energy attenuation layer, and (d) acorresponding point on a computerized reference surface.
 23. Theprotective sports helmet of claim 22, wherein the computerized referencesurface is a certified surface of a computerized safety standard. 24.The protective sports helmet of claim 22, wherein the energy attenuationlayer includes a lattice structure formed using a three dimensionalprinter.
 25. The protective sports helmet of claim 22, wherein thephysical helmet shell is utilized when the computerized referencesurface is not penetrated by a computerized representation of an outersurface of the player's head.
 26. The protective sports helmet of claim25, wherein the computerized representation of an outer surface of theplayer's head is created from head data obtained using either: (i) ahand-held non-contact scanning device or (ii) a mechanical measurementdevice that includes contact probes.
 27. The protective sports helmet ofclaim 25, wherein the inner surface of the energy attenuation layer hasa topography that conforms to a surface that is derived from thecomputerized representation of the outer surface of the player's head.28. The protective sports helmet of claim 22, wherein the energyattenuation layer includes a plurality of separately formed paddingcomponents.